Ultradur® (PBT)
Product Brochure
Ultradur® in the web: www.ultradur.de
Ultradur® (PBT )
Ultradur® is BASF’s trade name for its line of partially crystalline saturated polyesters. This line is based on polybutylene terephthalate and is employed in applications demanding a high performance level such as load bearing parts in
different industrial sectors. Ultradur® is outstanding for its
high rigidity and strength, very good dimensional stability,
low water absorption and high resistance to many chemicals. Moreover, Ultradur® exhibits exceptional resistance to
weathering and excellent heat aging behavior.
Ultradur® (PBT )
Ultradur® in automotive engineering
4 - 5
Ultradur® in electrical engineering and electronics
6 -7
Ultradur® in industrial and household applications
8 - 9
10 - 25
THE PROPERTIES OF Ultradur®
Product range
Mechanical properties
Tribological properties
Thermal properties
Electrical properties
Fire behavior
Resistance to chemicals and behavior on exposure to weather
10
14
19
20
22
23
24
26 - 39
THE PROCESSING OF Ultradur®
General notes
Injection molding
Extrusion
Fabrication and finishing processes
26
28
34
38
40 - 46
GENERAL INFORMATION
Safety notes
Delivery
®
Ultradur and the environment
Quality and environmental management
Nomenclature
Subject index
40
40
41
41
42
44
4
Ultradur® in automotive engineering
Ultradur® in automotive engineering
Ultradur® shows its strengths wherever high-quality and
above all heavy-duty parts are required – for example in
the automotive industry. Ultradur® is rigid, impact resistant,
dimensionally stable, heat and weather resistant as well
as resistant to fuels and lubricants. It shows an excellent
electrical and thermal long term behavior – all properties
that have made Ultradur® an indispensable ma­terial in many
applications in modern automotive e
­ ngineering.
Ultradur® is used in windscreen wiper arms, door handles, headlamp ­structures, mirror systems, connectors,
sun-roof components, in housings for locking systems
and in many other applications.
A feature that is particularly important for automotive electronics is the low water absorption and thus the fact that
the mechanical and electrical properties are largely independent of the moisture content or the climatic conditions
of use. Particularly for components that have an impact on
safety and have to work reliably for the entire lifetime of a
car, Ultradur® is indispensable. The range of applications
in automotive electrics includes plug-in connectors, sensors, drives and the full range of control units including the
safety-relevant ABS/ESP systems, airbag control units, or
electric steering systems.
Windscreen wiper arm
Mirror actuator
housing
Rain sensor
Ultradur® in automotive engineering
Mirror arm
Reflector housing
Headlamp housing
5
6
Ultradur® in electrical engineering and electronics
Ultradur® in electrical engineering
and electronics
Wherever electricity flows, plastics need to have excellent
electrical properties, good mechanical values and a high
level of dimensional stability under heat. In daily operation,
they ensure electrical insulation and thus protection if they
are touched. Thanks to its special combination of properties, Ultradur® is an ideal material for many applications in
the field of electrical engineering and electronics. As well
as showing outstanding dimensional stability and excellent
long-term electrical and thermal performance, it can be
modified in versatile ways, e. g. with regard to enhanced
flowability, strong hydrolysis resistance, low warpage, excellent laser-welding and laser-markable properties, as well as
very good flame-retardant characteristics.
Ultradur® is used among other things for electrical installations in railway cars, circuit breakers, plug-in connectors
and electronic switching elements for increased voltages
(e. g. railway cars, alternative drives, photovoltaic installations).
Connector
Connector
Plug-in connector
Connector
Ultradur® in electrical engineering and electronics
Travel adapter
Connector
Drill hammer
Motor circuit breaker
7
8
Ultradur® in industrial and household applications
Ultradur® in industrial
and household applications
The high rigidity, strength and outstanding dimensional
stability of Ultradur® remain comparatively unaffected by
external factors such as humidity.
Window profile reinforcement
The range of applications which benefit from these properties of Ultradur® in both industry and everyday life is vast
and comprises:
packaging, e. g. films or paper coatings
fibers for bristles, screen meshes, or nonwovens
toys with correspondingly high requirements on the
plastic’s safety
masterbatches as additives for thermoplastics
sanitary products and applications for irrigation
technology
metal replacement in window profiles for boosting energy efficiency
components of household appliances such as
refrigerators and coffee machines
These products also benefit among other things from the
excellent sterilization, high surface quality, compliance with
food safety regulations, and the approval for the drinking
water sector of the corresponding Ultradur® grades.
Insulin pen
Ultradur® in industrial and household applications
Bristle filaments
Toy
Film
Compressor
9
10
THE PROPERTIES OF Ultradur®
Product range
The properties of Ultradur®
The Ultradur® grades are polyalkylene terephthalate molding compounds based on polybutylene terephthalate. The
chemical structure is illustrated in the following structural
formula:
O
C–
O
–C–O–CH 2–CH2–CH2–CH2–O
n
Ultradur® is produced by poly­con­densation of terephthalic
acid or dimethyl terephthalate with 1,4 -butanediol using
special catalysts. Terephthalic acid, dimethyl terephthalate
and 1,4 -butanediol are obtained from petrochemical feedstocks, such as xylene and acetylene.
Product range
The most important applications of Ultradur® are automotive
engineering, electrical engineering, electronics and telecommunications as well as precision engineering and general
mechanical engineering. For these applications, a variety of
Ultradur® types is available. When selecting the most suitable types for your specific purpose our technical support
will be glad to help.
Unreinforced grades
The Ultradur® range includes a variety of PBT grades which
differ in their flow properties, demolding and setting behavior.
The unreinforced grades are used for parts with very good
surface quality, with applications ranging from packaging
film to filigree connectors in electrical engineering and functional parts such as gear wheels.
Reinforced grades
Ultradur® demonstrates the full potential of its positive
properties in a wide range of glass-fiber reinforced grades.
Depending on what is required, the Ultradur® range includes standard grades with glass fiber contents of up to
50 percent. Processed to molded parts, these Ultradur®
grades are key players in assemblies that withstand high
mechanical stress even at elevated temperatures, such as
in the engine compartment of cars.
In addition to the pure PBT/glass fiber compounds, the range
of reinforced grades also includes glass-fiber reinforced PBT
blends which have been further optimized with regard to
surface quality and dimensional stability. Well-known manufacturers of electronic assemblies have confidence in the
reinforced Ultradur® grades as a housing material because
of its outstanding performance profile and high consistency of
product quality.
Reinforced Ultradur® grades with enhanced
flow properties
With the innovative Ultradur® High Speed grades, it is possible not only to fill intricate molds, but also to significantly
reduce cycle times compared with standard materials. These
particularly economic Ultradur® High Speed grades have different glass-fiber contents and are also available as PBT/ASA
blends, the S 4090 grades.
Reinforced Ultradur® grades with particularly
low warpage
Manufacturing large, dimensionally stable parts, e. g. ventilation grids in cars, is a major challenge for plastic processors.
The warpage-reduced grades make processing easier. These
materials have lower contents of anisotropic fillers and reinforcing materials. At special settings, it is possible to achieve
roughly equal processing rates in longitudinal and transverse
direction – the best conditions for the production of visible
low-warpage parts.
THE PROPERTIES OF Ultradur®
Product range
11
Reinforced Ultradur® grades with particularly good
hydrolysis resistance
Special additives make the robust Ultradur® even more
resistant if it is exposed to water or moisture at elevated
temperatures. It was possible to show in various test systems that these specialty grades are resistant to hydrolytic
attack for much longer than standard PBT. Further information on Ultradur® HR can be found in the brochure “Ultradur®
HR – PBT for hot-damp environments”.
Ultradur® for applications in contact with food and
drinking water
With the suffixes FC (Food Contact) and Aqua®, Ultradur®
grades are offered specifically for components that come
into contact with food and drinking water. The Ultradur® FC
grades make it possible to develop applications in contact
with food and to meet the different food safety regulations,
e. g. FDA, European Food Contact No. 2002 / 72 / EC and
GMP (EC) No. 2023/2006.
Reinforced Ultradur® grades with outstanding laser
transparency
In principle, laser welding of partially crystalline thermoplastics is more difficult than that of amorphous plastics as the
laser beam is scattered on the spherulites. This problem,
which is shared by all partially crystalline plastics, was particularly pronounced with PBT: Ultradur® LUX now provides
a partially crystalline PBT with optical properties that have
never been reached before. In comparison with conventional
PBT, Ultradur® LUX lets through much more laser light; the
widening of the beam is much lower.
Ultradur® FC Aqua® grades have the approvals in accordance
with the KTW, DVGW and WRAS guidelines in cold water
applications. The special requirements on plastics that come
into contact with drinking water include particularly low
migration values, a high level of taste neutrality and the confirmation that long-term contact with the plastic will not cause
accelerated algae growth. More detailed information about
the Aqua® range can be found in the brochure “From the
idea to production. The Aqua® plastics portfolio for the sanitary and water industries”.
The improved laser transparency means that considerably
higher welding speeds are now possible, and at the same
time the process window is much wider. Thicker components for joining can also be welded than was previously the
case. This gives access to applications that were previously
reserved for other joining methods. More detailed information about Ultradur® LUX can be found in the brochure
“Ultradur® LUX – PBT for laser welding”.
Flame-retardant grades
Many flame-retardant grades are available in the product
range. Ultradur® for applications in the construction and
electrical appliances sectors, which place special requirements on PBT’s flammability. The standard fire-retardant
grades are unreinforced and available with 10, 20, or 30
percent glass-fiber reinforcement.
Air flow control
Ultradur® for medical applications
Ultradur® B 4520 PRO is suitable in particular for injection
molding applications in the medical sector. It is noted for
its low warpage and shrinkage behavior. This means that
Ultradur® B 4520 PRO is able to meet the strict requirements placed on medical components in terms of dimensional stability. Other advantages that are significant for use
in medical equipment include the low water absorption and
the excellent resistance to many chemicals that are used in
the medical sector.
Ultradur® B 4520 PRO can be easily printed using hot stamping as well as pad printing processes. Among other things,
gamma rays or ethylene oxide are used for sterilizing the components. More detailed information about Ultradur® PRO can
be found in the brochure entitled “Engineering plastics for
medical solutions – Ultraform® PRO and Ultradur® PRO”.
12
THE PROPERTIES OF Ultradur®
Product range
Unreinforced grades
B 2550
Easy-flowing grade for coating paper and board with high heat resistance, for example for packaging
of frozen goods and ready-prepared meals. Also suitable for injection-molding applications with
demands on the flowability and for the manufacture of fibers in the spinning process.
B 4500
B 4520
Medium-viscosity grade for manufacturing films, monofilaments, bristles and batches and for thin-walled profiles
and pipes. The grade is also suitable for the manufacture of industrial functional parts in injection-molding.
B 6550
B 6550 L / LN
High-viscosity grades for the extrusion of loose buffer tubes for optical fibers and boards, semi-finished products
for machining, profiles and pipes.
Unreinforced grades with good flowability
B 4520 High Speed
Easy-flowing injection-molding grade for the manufacture of connectors and other industrial parts.
Reinforced grades
B 4300
G2 / G4 / G6 / G10
Injection-molding grades with 10 % to 50 % glass fibers, for industrial parts, rigid, tough and dimensionally stable,
for example for thermostat parts, small-motor housings for vehicles, headlamp frames, cams, windshield wiper
arms, plug-in connectors, housings, consoles, contact mounts and covers.
B 4040 G4 / G6 / G10
Injection-molding grades with 10 % to 50 % glass fibers for industrial parts with excellent surface quality, for example for door handles in vehicles, sunroof frames, oven door handles, toaster casings, exterior mirrors, rear screen
wiper arms in vehicles and sunroof wind deflectors.
S 4090 G2 / G4 / G6
Low-warpage, easy flowing injection-molding grades with 10 % to 30 % glass fibers for industrial parts with high
dimensional stability requirements, for example for plug-in connectors and housings.
S 4090
GX / G4X / G6X
Low-warpage, easy-flowing injection-molding grades with very good processing properties, with 14 % to 30 %
glass fibers, for industrial parts with high dimensional stability requirements, for example for internal applications
for vehicles, plug-in connectors and housings.
Reinforced grades with excellent flowability
B 4300
G2 / G3 / G4 / G6
High Speed
Easy-flowing injection-molding grades with 10 % to 30 % glass fibers, for industrial parts, rigid, tough and
dimensionally stable, for example for housings, consoles, plug-in connectors, contact carriers and covers.
B 4040 G6
High Speed
Easy-flowing injection-molding grade with 30 % glass fibers for industrial parts with excellent surface
quality, for example door handles in vehicles, sunroof frames, exterior mirrors and windshield wiper arms.
S 4090 G4/G6
High Speed
Low-warpage, easy-flowing injection-molding grades with 20 % or 30 % glass fibers for industrial parts with high
dimensional stability requirements, for example for internal applications for vehicles, plug-in connectors and
housings.
Reinforced grades with low warpage
B 4300 K4 / K6
Injection-molding grades with 20 % to 30 % glass beads for industrial parts with low warpage, for example
precision parts for optical instruments, chassis, housings (including gas meter housings).
B 4300 M2 / M5
Mineral-reinforced, impact-modified injection-molding grades for rigid parts with good surface quality and low
warpage, for example central automotive door locks, housings and visible parts of domestic appliances.
B 4300 GM42
Mixed glass-fiber-reinforced and mineral-reinforced injection-molding grade with good surface quality and rigidity
and with low warpage for parts such as housings and printed circuit boards.
S 4090 GM11 / 13
Injection-molding grades reinforced with 10 % to 20 % of glass fibers/minerals, for laminar parts with
high dimensional stability requirements and low warpage, for example lids, ventilation grilles and housing covers.
THE PROPERTIES OF Ultradur®
Product range
13
Flame-retardant grades
B 4406 unreinforced / G2 / G4 / G6
Flame-retardant injection-molding grades, unreinforced or with 10 % to 30 % glass fibers, for parts requiring
enhanced flame-retardance, for example plug-in connectors and housings, coil formers and lighting components.
B 4441 G5
Halogen-free flame-retardant injection-molding grade with 25 % of glass fibers for parts requiring enhanced
flame-retardance. Specially optimized for the filament requirements of IEC 60335 for increased tracking
resistance, for example for plug-in connectors, switch parts and housings for domestic appliances.
B 4450 G5
Halogen-free flame-retardant injection-molding grade with 25 % glass fibers for parts requiring enhanced flameretardance as well as maximum tracking resistance, for example for plug-in connectors, switch parts or housings
for power electronics.
B 4450 G5 HR
Halogen-free flame-retardant injection-molding grade with 25 % glass fibers for parts requiring enhanced
flame-retardance as well as maximum tracking resistance and additionally meeting the requirements in terms
of hydrolysis stability.
Reinforced grades with outstanding hydrolysis resistance
B 4330 G3 / G6 HR
Impact-modified injection-molding grade with 15 % or 30 % glass fibers, for industrial parts with increased
demands on the hydrolysis stability, increased resistance to alkaline solutions and toughness, for example for
housings and plug-in connectors in the engine compartment.
B 4300 G6 HR
Injection-molding grade with 30 % glass fibers, for industrial parts with increased demands on the hydrolysis
stability, for example for housings and plug-in connectors in the engine compartment.
Reinforced grades with particularly high laser transparency for laser welding
LUX B 4300 G4 / G6
Laser-weldable grades with 20 % or 30 % glass fibers; particularly high specified transparency for
radiation in the near infrared area (800-1100 nm), e. g. of Nd:YAG or diode lasers.
Grades with special properties
LS
Laser-markable products; can be marked with a Nd:YAG laser (1064 nm).
LT
Laser-transparent grades with specified laser transparency; for radiation in the near infrared area
(800-1100 nm), e. g. of Nd:YAG or diode lasers.
FC / FC Aqua®
Products suitable for use in drinking water and/or food contact. They meet the regulatory requirements for the
corresponding areas of use.
PRO
Products which meet the regulatory requirements in particular in the area of medical devices, such as insulin pens
or inhalers.
Table 1: Ultradur® product range
We also offer further products with special properties or for
special applications. For more information on products with
a special finish, please contact the Ultra-Infopoint.
14
THE PROPERTIES OF Ultradur®
Mechanical properties
The Ultradur® product range includes grades with various
mechanical properties such as rigidity, strength and impactresistance.
Ultradur® is distinguished by a balanced combination of
rigidity and strength with good impact-resistance, thermostability, sliding friction properties and excellent dimensional
stability.
Elongation at break [%]
Mechanical properties
B 4520
> 50
7
6
5
B 4300 G2
4
The strength and rigidity of glass-fiber reinforced Ultradur®
grades are substantially higher than those of the unreinforced Ultradur® grades. Figure 1 shows the dependence
of the modulus of elasticity and the elongation on the glass
fiber content.
2
B 4300 G10
1
0
2500
4400
7000
9800
16500
Modulus of elasticity [MPa]
Logarithmic decrement
Fig. 1: Modulus of elasticity and elongation at break
Shear modulus [MPa]
The good strength characteristics of the Ultradur® grades
permit high mechanical loads even at e
­ levated temperatures
( Figs. 3 and 4).
B 4300 G6
3
The shear modulus and damping values ( Fig. 2) measured
in torsion pendulum tests in accordance with ISO 6721-2
as a function of temperature provide useful insight into the
temperature-dependence of the properties of the reinforced
Ultradur® grades.
The pronounced maximum in the logarithmic decrement
at + 50 °C identifies the softening range of the amorphous
fractions while the crystalline fractions soften only above
+ 220 °C and thus ensure dimensional stability and strength
over a wide range of temperature.
B 4300 G4
10000
0.6
0.5
1000
0.4
100
0.3
B 4300 G6
S 4090 G6
B 4300 G6
S 4090 G6
0.2
10
0.1
1
-100
-50
0
50
100
150
200
250
Temperature [°C]
Fig. 2: Shear modulus and logarithmic decrement of
glass-fiber reinforced Ultradur® as a function of temperature ( in accordance with ISO 6721-2)
0
Tensile strength [MPa]
THE PROPERTIES OF Ultradur®
Mechanical properties
15
250
B 4300 G2
B 4300 G4
B 4300 G6
200
150
100
50
0
-50
-25
0
25
50
75
100
125
150
Temperature [°C]
Tensile strength [MPa]
Fig. 3: Tensile strength of glass-fiber reinforced Ultradur® B
as a function of temperature (in accordance with ISO 527,
take-off speed 5 mm /min)
250
S 4090 G2
S 4090 G4
S 4090 G6
Air pressure sensor
200
150
100
50
0
-50
-25
0
25
50
75
100
125
150
Temperature [°C]
Fig. 4: Tensile strength of glass-fiber reinforced Ultradur® S
as a function of temperature (in accordance with ISO 527,
take-off speed 5 mm /min)
16
The behavior under short, uniaxial tensile loads is demonstrated by stress-strain diagrams. Figure 5 shows the stressstrain diagram for unreinforced Ultradur® B 4520 and Figure
6 shows that for Ultradur® B 4300 G6 with 30 % glass fibers
as a function of temperature.
Tensile stress [MPa]
THE PROPERTIES OF Ultradur®
Mechanical properties
Toughness, impact strength and low-temperature
impact resistance
Impact strength may be specified, for example from the
stress-strain diagram, as the deformation energy at failure
( Figs. 5 and 6 ).
100
B 4520
80
-40 °C
60
-20 °C
0 °C
30 °C
23 °C
40
40 °C
50 °C
A further criterion for toughness is the impact resistance
of unnotched test rods in accordance with ISO 179/1eU.
According to Table 2 the impact resistance of unreinforced
­ igher than that of glass-fiber reinforced
Ultradur® B 4520 is h
Ultradur® grades.
20
80 °C
100 °C
60 °C
140 °C
120 °C
0
2
4
6
160 °C
8
10
Elongation [%]
Fig. 5: Stress-strain diagrams for unreinforced Ultradur® at
different temperatures (in accordance with ISO 527, take-off
speed 50 mm /min)
Modulus [MPa]
Stress [MPa]
Comparative values closer to practical conditions for the
impact properties of the materials under impact loads can
be measured by impact tests or falling weight tests in
accordance with DIN 53443. Based on this standard the
50 % impact-failure energy ( E 50 ), i. e. the falling energy at
which 50 % of the parts are damaged, was determined for
test boxes having a wall thickness of 1.5 mm (Table 2).
The failure energy is dependent on the dimensions, the
thickness of the walls, the reinforcement of the moldings
and on the processing conditions.
200
-40
0
23
40
80
120
160
180
160
140
14000
12000
10000
120
8000
100
6000
80
60
4000
40
2000
20
0
1
2
3
0
-50
4
Elongation [%]
0
50
100
150
200
Temperature [°C]
Fig. 6: Stress-strain diagrams for glass-fiber reinforced Ultradur B 4300 G6 at different temperatures ( in accordance with ISO 527,
take-off speed 5 mm /min)
®
THE PROPERTIES OF Ultradur®
Mechanical properties
Property
Glass content
Impact-failure energy (E 50 )
Impact strength + 23 °C
17
Unit
B 4520
B 4300 G2
B 4300 G4
B 4300 G6
B 4300 G10
Wt.- %
0
10
20
30
50
J
> 140
12
5
1.6
0.8
kJ / m2
no break
38
58
72
65
Behavior under long-term static loading
The loading of a material under a static load for relatively
long periods is marked by a constant stress or strain. The
tensile creep test in accordance with DIN 53444 and the
stress relaxation test in accordance with DIN 53441 provide
information about extension, mechanical strength and stress
relaxation behavior under sustained loading.
Creep modulus [MPa]
Table 2: Dependence of impact strength (ISO 179 / 1eU) and impact failure energy (E 50 ) (DIN 53443) on the glass fiber content
9000
8000
18 MPa
26 MPa
34 MPa
42 MPa
50 MPa
58 MPa
66 MPa
74 MPa
82 MPa
90 MPa
7000
6000
The results are illustrated as creep modulus plots, creep
curves and isochronous stress-strain curves ( Figs. 7 and 8).
These graphs are just a selection from the extensive plastics
database CAMPUS®.
5000
4000
3000
10
100
1000
10000
10000
Duration [h]
100
100
23 °C
80
10 h
100 h
1000 h
10000 h
100000 h
60
40
20
100
80
60
40
1
2
3
Elongation [%]
20
0
60
40
0
100
120 °C
10 h
100 h
1000 h
10000 h
100000 h
80
90 °C
10 h
100 h
1000 h
10000 h
100000 h
20
Tensile stress [MPa]
Tensile stress [MPa]
0
Tensile stress [MPa]
Tensile stress [MPa]
Fig. 7: Creep modulus curves for Ultradur® B 4300 G6 at
23 °C
80
60
40
1
2
3
Elongation [%]
2
3
Elongation [%]
160 °C
10 h
100 h
1000 h
10000 h
100000 h
20
1
2
3
Elongation [%]
0
1
Fig. 8: Isochronous stress-strain curves for Ultradur® B 4300 G6 under normal conditions acc. to DIN 50014-23 / 50-2 and at 90 °C,
120 °C and 160 °C acc. to DIN 53442
18
THE PROPERTIES OF Ultradur®
Mechanical properties
Stress max. [MPa]
Behavior under cyclic loads, flexural fatigue strength
Engineering parts are frequently subjected to alternating or
cyclic loads, which act periodically in the same manner on
the structural part. The behavior of a material under such
loads is determined in long-term flexural fatigue tests or in
rotating bend­ing fatigue tests (DIN 53442) up to very high
load-cycle rates. The results are presented in Wöhler diagrams obtained by plotting the applied stress against the
load-cycle rate achieved in each case (Fig. 9 ). The flexural
fatigue strength is defined as the stress level a sample can
withstand for at least 10 million cycles.
100
It can be gathered from the illustration that in the case of
Ultradur® B 4300 G6 the flexural fatigue strength under normal conditions is 40 MPa.
When applying the test results in practice it has to be taken
into account that at high load alternation frequencies the
parts may heat up considerably due to internal friction. In
such cases, just as at higher operating temperatures, lower
flexural fatigue strength values have to be expected.
S-N curve
90
80
70
60
50
40
30
5
104
2
105
5
2
5
106
2
5
107
2
Cycles
Fig. 9: Flexural fatigue strength of Ultradur B 4300 G6 under normal conditions as defined by DIN 50014-23 / 50-2 in accordance
with DIN 53442, injection-molded test specimen
®
THE PROPERTIES OF Ultradur®
Tribological properties
19
Ultradur® is suitable as a material for sliding elements due
to its excellent sliding properties and very high resistance
to wear.
Figures 10 and 11 show examples of friction values and
wear rates for unreinforced and glass-fiber reinforced
Ultradur® on a special tribological system having two
different depths of roughness. Sliding properties depend
strongly on the system so that tailor-made tests to the part
in question might be necessary. The coefficient of sliding
friction and the wear rate due to sliding friction depend
on the contact pressure, the temperature of the sliding surfaces and the sliding distance covered. The surface roughness and the hardness of the paired material is decisive.
The sliding speed has no appreciable effect if heating and
modification of the sliding surfaces are avoided.
Coefficient of sliding friction [µ]
Tribological properties
0.70
S 4090 G6
S 4090 G4
B 4300 G6
B 4520
0.60
0.50
0.40
0.30
0.20
0.10
0.00
1
2
3
4
5
6
7
8
9
10 11
12
Wear rate due to sliding friction WI / s [µm / km]
Pressor sensor
Coefficient of sliding friction [µ]
Fig. 10: Coefficient of sliding friction and wear rates of unlubricated Ultradur® at 0.15 µm depth of roughness; tribological
system: pin-on-disk; base material: disk of 100 Cr 6 / 800 HV
steel; opposing­material: plastic; ambient temperature: 23 °C;
contact pressure: 1 MPa; sliding speed: 0.5 m /s
0.70
S 4090 G6
S 4090 G4
B 4300 G6
B 4520
0.60
0.50
0.40
0.30
0.20
0.10
0.00
1
2
3
4
5
6
7
8
9
10 11
12
Wear rate due to sliding friction WI/s [µm/km]
Fig. 11: Coefficient of sliding friction and wear rates of unlubricated Ultradur® at 3 µm depth of roughness; tribological system: pin-on-disk; base material: disk of 100 Cr 6 / 800 HV
steel; opposing material: plastic; ambient temperature: 23 °C;
contact pressure: 1 MPa; sliding speed: 0.5 m / s
20
THE PROPERTIES OF Ultradur®
Thermal properties
Thermal properties
Ultradur® is distinguished by a low coefficient of linear expansion. The reinforced grades in particular exhibit high dimensional stability when temperature changes occur. In the case
of the glass-fiber reinforced grades, however, the linear expansion is determined by the orientation of the fibers. Because
of glass fiber reinforcement, the dimensional stability on
exposure to heat ( ISO 75 ) increases significantly by comparison with unreinforced grades.
Behavior on brief exposure to heat
Apart from the product-specific thermal properties the
behavior of Ultradur® components on exposure to heat also
depends on the d
­ uration and mode of application of heat
and on the loading. The shape of the parts is also important. Accordingly, the dimensional s­ tability of Ultradur® parts
cannot be estimated simply on the basis of the temperature
values from the various standardized tests.
The shear modulus and damping values measured as a
function of temperature in torsion pendulum tests in accordance with ISO 6721-2 afford valuable insight into the temperature behavior. A comparison of shear modulus curves
(Fig. 2) gives information about the different thermomechanical
effects at low deformation stresses and speeds. Based on
practical experience the thermal stability of well-manufactured parts is in accordance with the temperature values
measured in the torsion pendulum tests in which the start
of softening becomes apparent.
Heat aging resistance
Thermal aging is the continuous, irreversible change (degradation) of properties under the action of elevated temperatures. The determination of the aging characteristics of finished parts under operational conditions is often difficult to
carry out because of the long service life required.
The test methods developed for thermal aging using standardized test specimens make use of the increasing reaction rate of chemical pro­cesses at higher temperatures. This
dependence of service life on temperature described mathematically by the Arrhenius equation is the basis of the international standards IEC 60216, ISO 2578 and the US standard UL 746B.
The temperature index ( TI ) is defined as the temperature in
°C at which the permitted limiting value (usually decline of
the property to 50 % of the initial value) is reached after a
defined time (usually 20,000 hours). The temperature index
is available for many products and various properties (e. g.
tensile strength). The temperature indices are given in the
Ultradur® product range.
In Figure 12 the tensile strength of Ultradur® B 4300 G6 is
plotted as a function of storage time and storage temperature. From the graph a temperature-time limit in accordance
with IEC 60216 of approx. 140 °C after 20,000 hours can
be extrapolated on the basis of a 50 % decline in tensile
strength (Fig. 13).
Time [h]
As a partially crystalline plastic, Ultradur® has a narrow melting range between 220 °C and 225 °C. The high crystalline
component makes it possible for stress-free Ultradur® moldings to be heated for short periods to just below the melting
temperature without undergoing deformation or degradation.
100000
B 4300 G6
10000
1000
130
140
160
180
Temperature [°C]
Fig. 12: Thermal endurance graph for glass-fiber reinforced
Ultradur® ( IEC 60216)
Tensile strength [MPa]
Tensile strength [MPa]
THE PROPERTIES OF Ultradur®
Thermal properties
160
140
120
100
160
Ultradur® B 4330 G6 HR
reference without HR stabilization
140
120
100
80
120 °C
150 °C
180 °C
60
80
60
40
40
20
20
0
21
1000 2000 3000 4000 5000 6000 7000 8000 9000
Time [h]
Fig. 13: Heat aging of Ultradur B 4300 G6
®
Ultradur® moldings become only slightly discolored on long
exposure to thermal stress in the aforementioned temperature-time limits. In the case of uncolored Ultradur® B 4520
for example, only a very slight change in color can be observed after exposure to a temperature of 110 °C for 150
days. Even after storage for 100 days at 140 °C discoloration
due to oxidation is slight, i. e. the material is suitable for visible parts exposed to high temperatures, e. g. in the domestic appliance sector.
Hydrolysis resistance
With polyesters, contact with water – even in the form of
atmospheric moisture – results, especially at elevated temperatures, in hydrolytic splitting of the polymer chains and
thus in a weakening of the material. Important material
properties such as strength, elasticity and impact strength
suffer, if the material is hydrolytically damaged. In applications in which moisture can have an effect at higher temperatures over a relevant period of time, for example in automotive electronics, additives are generally added as hydrolysis
stabilizers. These additives serve to counteract the chain
splitting through hydrolysis, greatly slow down hydrolytic
degradation and can thus prolong the life of a component
many times over (Fig. 14).
0
50
100
150
200
250
300
350
Aging time [d ]
Fig. 14: Comparison of PBT GF30 without HR stabilization to
Ultradur® B 4330 G6 HR: aging at 85 °C / 85 % rel. humidity,
tensile properties for 4 mm thick specimen ( ISO 527, 1A)
The development of hydrolysis-stabilized Ultradur® grades
provides processors with materials which combine the proven excellent properties of Ultradur® with a much higher level
of resistance to the effects of moisture. This means that even
applications in the highest stress classes can be achieved.
BASF offers a series of HR-modified Ultradur® grades which
are noted not only for having high hydrolysis resistance, but
also offer processing benefits. In addition to B 4300 G6 HR,
the range also comprises the impact-modified grades
B 4330 G3 and G6 HR.
22
THE PROPERTIES OF Ultradur®
Electrical properties
Figure 15 shows the dielectric constant and the dissipation
factor as a function of frequency with reference to Ultradur®
S 4090 G4. The electrical properties are not affected by the
moisture content of the air.
5.0
0.03
S 4090 G4
4.0
3.0
0.02
r
tan δ
0 1
10
102
0.01
103
104
105
106
107
108
109
Frequency [Hz]
Fig. 15: Dielectric constant and dissipation factor for
glass-fiber reinforced Ultradur® as a function of frequency
Headlight cover
Dissipation factor tan δ
Ultradur® is of great importance in electrical engineering
and electronics. It is used in insulating parts, such as plug
boards, contact strips and plug connections for example,
due to its balanced range of properties. These include good
insulation properties (contact and surface resistance) in
association with high dielectric strength and good tracking
current resistance together with satisfactory behavior on
exposure to heat, in aging, and the possibility of meeting the
requirements for increased fire safety by incorporation of
flame-retardant additives. Electrical test values are compiled
in the Ultradur® product range.
Dielectric constant r
Electrical properties
THE PROPERTIES OF Ultradur®
Fire behavior
23
Fire behavior
General notes
In the temperature range above 290 °C, flammable gases
are formed. They continue to burn after they have been
ignited. These processes are affected by many factors so
that, as with all flammable solid materials, no definite flash
point can be specified. The use of flame-retardant additives
is intended to prevent fires from occurring in the first place
(inflammation) or in the event of a fire minimize its spread
(self-extinguishment). The decomposition products formed
from charring and combustion are mainly carbon dioxide
and water and, depending on the supply of oxygen, small
amounts of carbon monoxide and tetrahydrofuran.
Tests
Electrical engineering
Different material tests are carried out to assess the fire
behavior of electrical insulating materials. In Europe, the
glow wire test according to IEC 60695-2-10 ff is frequently
required. Another test carried out on rod-shaped samples is
the classification according to “UL 94 – Standard, Tests for
Flammability of Plastic Materials for Parts in Devices and
Appliances” of Underwriters Laboratories Inc. / USA.
Transportation
In modern traffic and transport engineering, plastics make a
substantial contribution to ensuring the high performance
capacity of road vehicles and trains. Materials used inside
motor vehicles are governed by the fire safety requirements
according to DIN 75200 and FMVSS 302, which are met by
all Ultradur® grades with a wall thickness of up to 1 mm
(burning rate < 100 mm).
The corresponding values can be found in the Ultradur®
product range. For rail vehicles, in addition to different
national regulations, a European standard, EN 45545, is
drawn up which also contains requirements for the other
effects of fire such as the density and toxicity of smoke gas.
Construction industry
Building materials for use in construction are tested according to DIN 4102 Part 1 “Fire behavior of building materials
and components”. Panels made of unreinforced and glassfiber reinforced Ultradur® products (thickness of 1 mm, standard type of sample) are to be assigned) to the building
materials class B 2 as normal-flammability building materials
(designation in the Federal Republic of Germany).The classifications and measured results for the Ultradur® grades
regarding fire behavior are summarized in Table 3.
Further literature for electrical insulating materials
The wide variety of existing applications and sets of rules
can be difficult to comprehend. More detailed information
and key material figures can be found in the following BASF
brochures:
Engineering Plastics for the E / E Industry –
Standards and Ratings
Engineering Plastics for the E / E Industry –
Products, Applications, Typical Values
Engineering Plastics for Automotive Electrics –
Products, Applications, Typical Values
Ultradur
UL 94
Glow wire test
IEC 60695 Part 2-12
FMVSS 302
(d ≥ 1 mm)
B 4520
HB (0.75 mm)
850 (≤ 2 mm)
reached
B 4300 G2 - G10
HB (0.75 mm)
750 (2 mm)
reached
B 4300 K4 -K6
HB (1.5 mm)
850 (3 mm)
reached
S 4090 G4 -G6
HB (0.7 mm)
750 (3 mm)
reached
B 4406 G2 -G6
V-0 (0.4 mm)
960 (1 mm)
reached
B 4441 G5
V-0 (0.4 mm)
960 (1 mm)
reached
B 4450 G5
V-0 (0.4 mm)
960 (1 mm)
reached
Table 3: Fire behavior
24
THE PROPERTIES OF Ultradur®
Resistance to chemicals and behavior on exposure to weather
Resistance to chemicals and behavior on
exposure to weather
At room temperature, Ultradur is only soluble in very special solvents, such as highly fluorinated alcohols. At elevated
temperatures, Ultradur® is also dissolved by mixtures of
o-dichlorobenzene and phenol, or tetrachloroethane and
phenol, as well as o-chlorophenol and dichloroacetic acid.
At room temperature, Ultradur® is resistant to water and
aqueous solutions of most salts. It shows limited resistance
to diluted acids and is not resistant to aqueous alkalis.
®
Polyesters can be damaged by hydrolysis; brief contact with
warm or hot water does not pose any problems (Fig. 16).
For long-term use, it is advisable to use hydrolysis-resistant
Ultradur® HR grades.
Further information about the effect of solvents and chemicals
can be found in the brochure “Ultramid®, Ultradur®, Ultraform® –
Resistance to chemicals” and also at www.plasticsportal.eu.
Model investigations in the laboratory allow a relative comparison between different materials and thus represent a basis
for preselecting suitable materials for a specific application.
However, they cannot generally serve as a substitute for a
realistic test.
Moisture content [Wt.-%]
Resistance to chemicals
Ultradur® is highly resistant to many common solvents,
such as alcohols,­ethers, esters, higher aliphatic esters and
aliphatic hydrocarbons, and to fats and oils, such as fuels,
brake fluid and transformer oils.
0.6
B 4520 un
0.5
0.4
0.3
0.2
Climate storage at 85 °C / 85 % rel. h.
0.1
0
10
20
30
40
50
60
Storage time [h]
Fig. 16: Absorption of moisture by unreinforced Ultradur as
a function of time ( plaque thickness 2.5 mm)
THE PROPERTIES OF Ultradur®
Resistance to chemicals and behavior on exposure to weather
Behavior on exposure to weather
As has been shown by 3-year exposure to weather in the
open in Central Europe, moldings made from Ultradur® tend
to discolor only very slightly and their surface scarcely changes. Mechanical ­properties too, such as rigidity, tensile strength
and tear strength, are hardly affected. After a weathering
test for 3,600 hours in the Xenotest 1200 device the values
for tensile strength still amount to 90 % of the initial value.
On the other hand elongation at break is more adversely
affected. Using Xenotest 1200 equipment, BASF simulated
five to six years of weathering in the open air. Parts for outdoor use should be manufactured from black-colored material in order to minimize the effect that the surface is damaged by UV light. Fiber-reinforced grades such as U
­ ltradur®
B 4040 G4 / G6 / G10 with outstanding surface quality and
high resistance to UV radiation are suitable for parts subject to ­particularly extreme exposure. These grades have
outstanding surface quality and exhibit high resistance to
UV radiation.
Exterior mirror housing
25
26
THE PROCESSING OF Ultradur®
General notes
The processing of Ultradur®
General notes
As a general rule Ultradur® can be processed by all methods
known for ­thermoplastics. The main methods, h
­ owever, are
injection molding and extrusion. Complex moldings are economically manufactured in large numbers from Ultradur® by
injection molding. The extrusion­process is used to produce
film, semi-finished products, pipes, profiled parts, sheet and
mono­filaments. Semi-finished products are for the most part
ma­chined further by means of cutting tools to form finished
moldings.
The following text examines various topics relating to
the injection molding and extrusion of Ultradur®. Further
general and specific information can be found on the
internet via www.plasticsportal.eu or at the Ultra-Infopoint,
ultraplaste.infopoint@basf.com. More detailed information
on the injection molding of individual products is provided
in the respective processing data sheets.
Roof top frame
Moisture and drying
Thermoplastic polyesters such as polybutylene terephthalate
( PBT) are susceptible to hydrolysis. If the moisture content
­during fusion in the course of processing is too high, degradation will occur. This results in cleavage of the molecular
chains and hence in a reduction in the mean molecular weight.
In practice this manifests itself in a loss in impact resistance
and elasticity. The decline in strength usually turns out to be
less marked. Degradation of the material can be demonstrated
by determining the viscosity number according to DIN ISO
1628-5 or the melt volume index according to ISO 1133.
Particular care therefore has to be devoted to pretreatment
of the granules and processing in order to guarantee high
quality of the finished parts and low fluctuation in quality.
Ultradur® should generally have a moisture content of less than
0.04 % when being processed. In order to ensure reliable production, therefore, pre-drying should generally be the rule and
the machine should be loaded via a closed conveyor system.
Pre-drying is also recommended for the addition of batches,
e. g. in the case of self-coloring.
In order to prevent the formation of condensed water, containers stored in unheated rooms must only be opened
when they have attained the temperature in the processing
area. This can possibly take a very long time. Measurements
have shown that the interior of a 25-kg bag originally at 5 °C
had reached the temperature of 20 °C of the processing
area only after 48 hours.
THE PROCESSING OF Ultradur®
General notes
Of the various dryer systems possible, the dry air dryer has
proved to be technically and economically superior. Drying
times for these devices amount to 4 hours at 80 °C to 120 °C.
In general the directions of the equipment manufacturer
should be observed in order to achieve the desired drying
effect. The use of vented screws is inadvisable.
Production stoppages and change of material
During brief production stoppages the screw should be
advanced to the forwardmost position and when downtimes
are relatively long the barrel temperature should be additionally lowered. Before restarting after stoppages thorough
purging is required. When there is a change of material the
screw and barrel must be cleaned in advance. HDPE of
high molecular weight as well as glass-fiber reinforced
HDPE and GFPP have proved to have good cleaning action
in such cases.
27
Reprocessing
Reprocessing of reground parts and sprue is usually possible. Since degradation to a greater or lesser degree can
occur in each processing cycle, checks should first of all be
made as to how extensive this is. Checks on the viscosity
number in solution or the melt viscosity provide useful information. If the material was handled gently in the first pass
then as a rule up to 25 % of the regranulated material can
be mixed with the fresh granules without any decline in the
characteristics of the material.
In the case of flame retardant products limits to the quantity
of regrind permitted have to be observed (e. g. by means of
UL specifications). When regrind is added care has to be taken
that there is adequate predrying (see section on “Moisture
and drying”).
Self-coloring
Further shades other than those in our product range can
be made up by means of self-coloring using masterbatches.
When choosing the masterbatch attention should be paid to
a high level of compatibility with Ultradur® so that its range of
properties is not affected. We recommend PBT-based color
batches. In the case of flame-retardant products care must
be taken that only masterbatches are used which do not
change its rating (e. g. according to UL). The Ultra-Infopoint
will be happy to provide addresses of suppliers of suitable
masterbatches.
Pump pressure housing
28
THE PROCESSING OF Ultradur®
Injection molding
Injection molding
Injection unit
Single-flighted, shallow-cut three-section screws having a
L / D ratio of 20 - 23 are suitable for processing Ultradur®.
For the same screw diameter shallow flighted screws ensure
a shorter residence time of the melt in the cylinder and a more
homogeneous temperature distribution in the melt ( Figs. 17
and 18).
R
D hA
LA
S
hE
LK
LE
L
Mold design
For Ultradur® both conventional cold runners as well as hot
runner s­ ystems can be used. When using hot runner systems
and hot nozzles, systems heating from without are safer due
to the more homogeneous melt and a secure purging routine.
Diversions have to be designed in a manner favoring flow in
order to avoid deposits. Here furthermore, good thermal
isolation at the gate is important. In this way the temperatures
of the heated and cooled regions can be more directly controlled and the total energy requirements for heating and
cooling are reduced. The most suitable type of gate depends
on the specific application and must therefore be selected
for each case.
At mold temperatures above 60 °C the installation of thermal
insulation panels between the machine platen and the mold
base plate should be considered. As a result less heat energy
is lost and the temperature distribution in the mold is more
uniform.
D
L
LE
LK
LA
hA
hE
S
R
outer diameter of the screw
effective screw length
20-23D
length of the feed section
0.5 - 0.55 L
length of the compression section 0.25 - 0.3 L
length of the metering section
0.2 L
flight depth in the metering section
flight depth in the feed section
pitch
1.0D
non-return valve
Fig. 17: Screw geometry – terms and dimensions for threesection screws for injection-molding machines
Flight depth h [mm]
When processing GF-reinforced PBT types hard-wearing
steels should be used for the cylinder, screw and non-return
valve. At higher holding pressures the non-return valve must
also prevent backflow of the melt out of the front of the screw
so that sink marks or voids in the part are reliably avoided.
The need for a check on the adequacy of sealing or excess
play is always indicated when the melt cushion in the filled
mold reduces markedly in the holding phase. Due to the
viscous melt Ultradur® can be processed both with an open
nozzle as well as with a shut-off nozzle. The use of nozzle
heater bands is recommended.
20
hE = flight depth feed section
hA = flight depth metering section
18
16
standard screw
shallow screw
14
12
10
8
hE
6
4
2
hA
0
30
80
130
180
Screw diameter [mm]
Fig. 18: Screw flight depths for three-section screws in
injection-­molding machines
Temperature control in the mold should be so effective that
even over long production periods the desired temperatures
are attained in all contour-forming regions or selective temperature changes can be produced at particular points by
means of independent temperature control circuits. The quality
of an effective cooling system is shown in that temperature
fluctuations during the cycle phase are as small as possible.
Draft angels of 1° per side allow problem-free demolding.
Peripheral speed [m/min]
THE PROCESSING OF Ultradur®
Injection molding
60
60 mm
Screw diameter
50
45 mm
40
30
Metering and back pressure
When metering in, the peripheral screw speed and the level
of back pressure have to be limited with a view to gentle
handling of the material. Gentle infeed is guaranteed for
peripheral screw speeds of up to 15 m /min. Figure 19 shows
the speeds to be set as a function of the screw diameter.
The screw speed should be chosen so that the time available in a cycle for plastification is largely used up. The
back pressure, which should ensure improved homogeneity of the melt and is therefore desirable, should be limited
to 100 bar due to the risk of excessive shear. Good feed
behavior is best achieved by means of rising temperature
control. This is illustrated in Figure 20.
29
30 mm
Maximum recommended
speed 15 m /min
20
20 mm
10
15 mm
50
0
100
150
200
250
300
Rotary speed [ U/min ]
Fig. 19: Peripheral screw speed as a function of rotary speed
and screw diameter
Heater bands
6
5
4
3
2
1
Hopper
260
260
60
240
235
60
Temperature control [ °C ]
steady
260
260
260
260
rising
260
255
250
245
Fig. 20: Examples of cylinder temperature control for Ultradur®
30
THE PROCESSING OF Ultradur®
Injection molding
Processing temperature and residence time
The recommended range of melt temperatures for the various Ultradur® grades is 250 °C to 280 °C. In order to work
out the optimum machine setting a start should be made at
the temperature of 260 °C. The choice of melt temperature
depends on the flow lengths and wall thickness and on the
residence time of the melt in the cylinder. Unnecessarily high
melt temperatures and excessively long residence times of
the melt in the cylinder can bring about molecular degradation.
Figure 21 shows an example illustrating how the viscosity
number acts as a measure of the molecular weight as a function of the melt temperature and residence time.
Viscosity number [cm3/g ]
Based on experience material degradation of less than 10 ml / g
to 12 ml / g based on the measured viscosity in solution of the
granules and the molding is tolerable. In the event of values
higher than this the processing parameters and pretreatment
should be checked. Detailed information is available in the
product-specific processing data sheet.
130
B 4520
240 °C
250 °C
260 °C
120
270 °C
280 °C
290 °C
300 °C
110
Mold surface temperature
Mold surface temperatures should lie in the range of 40 °C
to 80 °C for unreinforced materials and 60 °C to 100 °C for
reinforced materials, if needed also higher. These temperatures can usefully be attained using water systems as
tempering medium. In the case of components with high
demands on surface quality, especially in the case of glassfiber reinforced grades, care should be taken that the mold
surface temperature is at least 80 °C or higher.
Since the mold temperature has an effect on shrinkage,
warpage and surface quality it is of great importance for the
dimensional accuracy of parts. The effect of mold surface
temperature on shrinkage behavior is illustrated in Figures
24 to 28 with reference to the examples of Ultradur® B 4520
and B 4300 G6.
Flow behavior and injection speed
The speed at which the mold is injected has an impact on
the quality of the molded parts. Rapid injection encourages
even solidification and the quality of the surface especially in
the case of parts made of glass-fiber-reinforced Ultradur®.
However, with molded parts that have very thick walls, it may
be appropriate to reduce the injection speed in order to
avoid a free jet.
The flow behavior of plastic melts, which is of great importance for the injection of the mold, can be assessed in practical terms through what is known as the spiral test using
spiral molds on commercial injection molding machines. The
flow path covered by the melt – the length of the spiral – is a
measure for the flowability of the processed material. The
spiral lengths for some selected Ultradur® grades are given
in Figure 22.
100
90
80
70
60
0
10
20
30
40
Residence time in the plasticating unit [ min ]
Fig. 21: Reduction of viscosity number of Ultradur® test
specimens as a function of the melt temperature and
residence time in the plastication unit
Spiral length [mm ]
THE PROCESSING OF Ultradur®
Injection molding
500
450
Melt temperature 260 °C
Melt temperature 280 °C
400
350
300
250
200
150
100
50
0
B 4300 G2 B 4300 G4 B 4300 G6 S 4090 G4 S 4090 G6
Fig. 22: Flow behavior of glass-fiber reinforced Ultradur®
grades; spiral length as a function of melt temperature;
wall thickness 1.5 mm
31
Shrinkage
ISO 294-4 defines the terms and methods for measuring
the shrinkage in processing. According to this, shrinkage is
defined as the difference between the dimensions of the
mold and those of the molded part at room temperature. It
results from the volume contraction of the molding compound in the injection mold as a result of cooling, a change
in the aggregate condition and crystallization. It is determined by the geometry (free or impeded shrinkage) and the
wall thickness of the molded part. In addition, the gate position and size, the processing parameters and the storage
time and temperature also play a crucial role. The interaction
between these different factors makes it difficult to predict
the shrinkage exactly in advance.
A useful resource for the designer are the shrinkage values
determined on the board measuring 60 mm ∙ 60 mm, which
is molded via a film gate, for it shows the minimum and maximum shrinkage due to the high orientation of the direction
of flow. The value measured on the test box (Fig. 23) can
serve as a guideline for an average shrinkage that occurs in
a real component as the flow fronts tend to run concentrically from the gate pin here.
Guidelines for the shrinkage of the Ultradur® grades are
specified in the product range.
Mechatronic control unit
B
A
C
E
D
Fig. 23: Test box
A ≈ 107 mm
B ≈ 47 mm
C ≈ 40 mm
D ≈ 60 mm
E ≈ 120 mm
32
THE PROCESSING OF Ultradur®
Injection molding
In order to illustrate the effect of some of these parameters
the shrinkage is presented by way of example as a function
of the mold surface temperature for wall thicknesses of 1.5
and 3 mm for unreinforced Ultradur® B 4520 in Figure 24
and for glass-fiber reinforced Ultradur® B 4300 G6 in Figure
25. Additionally in this investigation the holding pressure
was varied in stepwise manner from 500 through 1000 to
1500 bar. The test component was a test box as shown in
Figure 23. The specified shrinkage values were measured
along the longitudinal direction of the box.
After storage for 60 days at room temperature only the molded parts produced at low mold temperatures exhibited small
dimensional variations. After tempering, i. e. hot storage for
24 hours at 120 °C, the same parts exhibited marked aftershrinkage, especially those produced at low mold temperatures. As the mold surface temperature rises aftershrinkage
steadily drops. This behavior should be taken into account
when designing parts for use at elevated operational tem-
On the other hand shrinkage in the direction of flow and
transverse to this is approximately the same in unreinforced,
mineral-filled and glass-bead filled products. Injection-moldings which due to their design tend particularly to warp
should therefore be manu­factured as far as possible from
these Ultradur® grades or from the lower-warpage glassfiber reinforced Ultradur® S grades. In many cases warpagefree moldings can be produced by differential temperature
control of the mold parts. Further information can be obtained
via www.plasticsportal.eu.
Shrinkage [%]
Warpage
The warpage of an injection-molded part is caused mainly
by differential shrinkage in the direction of flow and in the
direction transverse to this. Warpage is often particularly
noticeable in the case of glass-fiber reinforced materials. In
addition, this increases as the mold surface temperature
rises. The warpage is also dependent on the shape of the
molded parts, the wall thickness distribution, the gate position and the processing conditions.
Shrinkage [%]
Depending on the processing conditions, aftershrinkage of the
com­ponents can occur. Figure 26 for unreinforced Ultradur®
B 4520 and Figure 27 for glass-fiber reinforced Ultradur®
B 4300 G6 give an impression of how large aftershrinkage
can be as a function of the mold surface temperature.
peratures. The Ultradur® grades S 4090 G2-G6 represent
alternatives having lower shrinkage. Their shrinkage and
warpage behavior are compared with those of the Ultradur®
B 4300 and B 4040 grades (20 % GF ) in Figures 28 and 29.
B 4520
Melt temperature (MT) 260 °C
Wall thickness ≥ 3.0 mm
Wall thickness = 1.5 mm
500 bar
2.0
B 4300 G6
Melt temperature (MT) 260 °C
Wall thickness ≥ 3.0 mm
Wall thickness = 1.5 mm
1.0
1000 bar
500 bar
1500 bar
1.5
0.8
1000 bar
500 bar
1500 bar
1.0
0.6
1000 bar
1500 bar
0.4
0.5
0
20
30
40
50
60
70
80
90
Mold surface temperature [°C]
Fig. 24: Shrinkage as a function of mold temperature,
part thickness and holding pressure (500, 1000 and
1500 bar) for unreinforced Ultradur®
20
30
40
50
60
70
80
90
Mold surface temperature [°C]
Fig. 25: Shrinkage as a function of mold temperature,
part thickness and holding pressure (500, 1000 and
1500 bar) for glass-fiber reinforced Ultradur®
Shrinkage [%]
Shrinkage [%]
THE PROCESSING OF Ultradur®
Injection molding
Wall thickness 2 mm
33
1.5
Wall thickness 1 mm
1.0
5
2.0
0.8
5
0.6
1.5
0.4
1.0
4
3
2
4
0.2
1
0.5
20
3
1/2
B 4520
30
40
50
60
70
80
0
20
90 100 110 120 130
30
B 4300 G6
40
50
60
70
80
90
100 110 120
Mold surface temperature [°C]
Mold surface temperature [°C]
Fig. 27: Effect of mold temperature and post-molding conditions on the shrinkage of glass-fiber reinforced Ultradur®*
Fig. 26: Effect of mold temperature and post-molding
conditions on the shrinkage of unreinforced Ultradur®*
* Mold: test box, dimension measured A: 107 mm, melt temperature: 265 °C, holding pressure: 660 bar
1.2
parallel to melt flow
perpendicular to melt flow
1.0
Warpage [mm]
Shrinkage after 1h [%]
1st Shrinkage measured 1 hour after injection
2nd After shrinkage measured 24 hours after injection.
3rd After shrinkage measured 14 days after injection.
4th After shrinkage measured 60 days after injection.
5th After shrinkage measured after tempering ( for 24 hours at 120 °C).
1.5
1.0
0.8
1.0
0.8
0.6
0.42 1.25
0.38
1.0
0.25 0.67
0.4
0.5
0.3
0.2
B 4300 G4
B 4040 G4
S 4090 G4
Fig. 28: Shrinkage behavior of glass-fiber reinforced Ultradur®
(Test box with walls 1.5 mm thick; melt temperature = 260 °C;
mold surface temperature = 80 °C)
0
B 4300 G4
B 4040 G4
S 4090 G4
Fig. 29: Warpage behavior of glass-fiber reinforced Ultradur®
( Test box with walls 1.5 mm thick; melt temperature = 260 °C;
mold surface temperature = 80 °C)
34
THE PROCESSING OF Ultradur®
Extrusion
Extrusion
Applications, screw geometry
The following Ultradur® grades listed in order of rising
viscosity are available for extrusion:
Ultradur® B 2550 / B 2550 FC
Ultradur® B 4500 / B 4500 FC
Ultradur® B 6550 / B 6550 FC / B 6550 L / B 6550 LN
Ultradur® B 2550 is suitable for the production of monofilaments and bristles. Ultradur® B 4500 is suitable for the
extrusion of flat films, Ultradur® B 6550 for the extrusion of
thin-walled and thick-walled tubes, hollow and solid profiles
and semi finished parts.
Ultradur® B 6550 L and B 6550 LN have been developed
for producing buffer tubes used in fiber optic cables. Ultradur®
B 6550 L is additionally modified with lubricant for a better
feeding performance. Ultradur® B 6550 LN is recommended
when tubes with a higher stiffness are required.
Thin-walled pipes made from Ultradur® B 6550 L and
B 6550 LN are therefore in many cases suitable for fuel and
oil pipes, pneumatic and hydraulic control lines, pipes for
central lubrication systems, Bowden cables and other
cable systems.
The processing properties of these grades are similar to
those of polyamide 6. In general, therefore, the product can
be processed on machines suitable for polyamides. The
same is true for the screw geometry. Experience to date has
shown that all Ultradur® extrusion grades can be extruded
using the same three-section screws which have also proved
to be effective in the processing of polyamides.
For Ultradur® the compression section and the flight depth
ratio are even more important than for polyamide. The length
of the compression zone should, therefore, not exceed 4 - 5 D
and the flight depth ratio should be approximately 3 :1.
Extruded Ultradur® B 6550 LN profiles – circular, square and
hollow rods together with sheet and flat bars – are principally
used as semi-finished parts for machine-cutting to produce
engineering articles for which production by injection-molding
does not come into consideration due to the small numbers
involved.
Tubes made from Ultradur® B 6550 L and B 6550 LN are
resistant to fuels, oils and greases and show favorable sliding
friction and wear properties. The ability of Ultradur® tubes
to withstand compressive loads is remarkably high not only
at normal temperatures but also at higher temperatures.
They can for example withstand burst pressures higher by
at least a factor of 1.5 than polyamide tubes of comparable
size.
Fibers
35
THE PROCESSING OF Ultradur®
Extrusion
Production of semi-finished products and
profile sections
Ultradur® B 6550 and B 6550 LN is formed into circular,
square, square-section and hollow rods under pressure by
the cooled-die extrusion method, i. e. with cooled or temperature-controlled mold pipes. Due to the necessarily lengthy
residence time of the melt, the melt t­emperature has to be
kept as low as possible.
In contrast with polyesters based on polyethylene terephthalate the temperature of the cooled die in the case of
Ultradur® need not be elevated, i. e. temperature control can
be effected with water at room t­em­perature. If the melt
temperature has to be reduced due to increasing layer thickness it is, however, more favorable in respect of surface
quality and state of stress in the parts to operate with water
of higher ­tem­perature (60 °C to 80 °C; see the processing
example for the produc­tion of round-section rods in Table 4).
As with other partially crystalline thermoplastics, suitably
high pressures are also needed in the case of Ultradur® for
compensating for the volume shrinkage occurring on solidification of the melt.
Production of sheet
Ultradur® B 6550 LN sheet and slab, are produced on commercial, horizontally arranged installations having a sheet
die, three-roll polishing stack and a following take-off unit.
The sheet die should have lips which extend up close to the
nip. The temperature control of the rolls depends on the
sheet thickness in question and ranges from 60 to 170 °C
(for processing example see Table 5 ). The throughput and
off-take rate are matched to one another in such a way that
a small, ­uniform bead is formed over the width of the roll
ahead of the nip. The uniformity of this bead is of great
­importance for the t­olerances and surface quality of the
sheet.
Sheet dimensions
Extruder
Screw
– 3-section lengths
– Flight depths
780 mm ∙ 2 mm
ø 90 mm, L / D = 30
LE = 11,5 D, LK = 4.5 D, LP = 14 D
h1 / h2 = 14.0 / 4.3
Die
Rod diameter
Extruder
Screw
– Section lengths
– Flight depths
Temperature settings
– Adapter
– Die (heated part)
– Die (cooled part)
ø 60 mm
ø 45 mm, L / D = 20
L E = 9 D, L K = 3 D, L P = 8 D
h1 / h2 = 6.65 / 2.25
235 / 245 / 250 °C
240 °C
250 °C
20 °C
Screw speed
16 U / min
Melt pressure
approx. 30 bar
Take-off speed
27 mm / min
Output
5.9 kg / h
Table 4: Rod extrusion example for Ultradur® B 6550 LN
Temperature settings
– Hopper
– Barrel
– Adapter
– Die
Three-roll-stack
800 mm
40 °C
215 / 220 / 235 / 260 / 230 / 225 / 220 / 220 °C
230 °C
throughout 230 °C
300 mm roll diameter
Temperature
Screw speed
Melt temperature
top
center
bottom
34 U /min
256 °C
Take-off speed
0.76 m / min
Output
100.8 kg / h
Table 5: Sheet extrusion example for Ultradur® B 6550 LN
50 °C
115 °C
170 °C
36
THE PROCESSING OF Ultradur®
Extrusion
Production of tubes
Tubes made from Ultradur® B 6550 L and B 6550 LN with
diameters up to approx. 8 mm and a wall thickness of 1 mm
are produced by the vacuum water bath calibration method.
Both sizing tubes and sizing plates are suitable for calibration.
In both cases the internal diameter is chosen to be approximately 2.5 % greater than the desired outer diameter of the
tube to be produced. Based on experience this difference
corresponds to the shrinkage in processing. To achieve the
highest possible haul-off speeds with Ultradur® B 6550 L
and B 6550 LN, the ratio of the pipe die diameter to the
internal diameter of the sizing sleeve must range from about
2 : 1 to 2.5 : 1. The die gap of the pipe extrusion head should
be 3 to 4 times the size of the desired wall thickness of the
tube. A processing example for the production of tube is
described in Table 6.
Tube dimensions
Extruder
Screw
– Section length
– Flight depths
Temperature settings
– Extruder
– Adapter
– Die
Extrusion mold
– Die diameter
– Mandrel diameter
– Gap
ø 6 mm ∙ 1 mm
Production of film
Flat film made from Ultradur® B 4500 is manufactured by
the usual method using sheet dies and chill rolls. With
appropriate cooling the films have very good transparency
and at the same time they are rigid and have good surface
slip. A processing example is shown in Table 7. Ultradur®
B 4500 film of 12 - 100 µm gauge can be produced under
appropriate production conditions with high transparency,
good surface slip and high rigidity. The properties of such
films are given in Table 8. Adhesive-tape resistant vapor
deposition of aluminum is readily possible on these films.
The barrier properties are improved still further by the vapor
deposition. Ultradur® B 4500 monofilm or multilayer ( with
PE ) can be sterilized on their own and in composites without risk of damage using superheated steam at 120 °C
to 140 °C, ethylene oxide or ionizing radiation (2.5 · 104 J / kg).
They are therefore also suitable as a packaging material for
sterilized goods. The films made from Ultradur® B 4500 can
be oriented uniaxially or biaxially.
Ultradur® B 4500 monofilm can be welded by means of
ultrasonics. Joining is also possible using parting line welding based on the thermal impulse principle. In this case,
however, postcrystallization produces a white zone in the
area of the welded joint.
ø 45 mm, L / D = 20
LE = 9 D, LK = 3 D, L P = 8 D
h1 / h2 = 6.65 / 2.25
250 / 240 / 230 °C
225 °C
215 °C
14 mm
6.8 mm
3.6 mm
Dimensions
Screw
– Section lengths
– Flight depths
Screen pack
Die
Heater band
temperatures
Gauge approx. 30 µm, width 650 mm
D = 63.5 mm, L / D = 24
LE = 7 D, LK = 5 D, L P = 12 D
h1 / h2 = 8.5 / 2.5
400, 900, 2500, 3600 mesh count /cm2
width 800 mm, die gap 0.5 mm
230 /245 /255 / 265 °C, die 225 °C
Melt temperature
280 °C
Melt pressure
75 bar
Waterbath-vacuum
calibration unit
– Sizing plate diameter
– Water temperature
6.15 mm
19 °C
Chill rolls
– Temperature
– Diameter
approx. 55 °C
450 mm
Screw speed
72 U /min
Screw speed
40 U /min
Take-off speed
20 m / min
Take-off speed
26 m /min
Output
24 kg / h
Table 6: Processing example for the production of tubes from
Ultradur® B 6550 L und Ultradur® B 6550 LN
Output
44 kg / h
Table 7: Film extrusion example for Ultradur® B 4500
THE PROCESSING OF Ultradur®
Extrusion
Unit
Value
37
Test method
Diameter
Mechanical properties
Monofilaments
0.70 mm
Bristles
0.20 mm
Yield stress S
(para. & perp.)
MPa
30 - 35
ISO 527
Extruder
Tear strength S
(para. & perp.)
MPa
75 - 80
ISO 527
Screw
Strain at break S
(para. & perp.)
%
450 - 500
ISO 527
Die
– Die head diameter
– Die head length
2.4 mm
4.8 mm
0.65 mm
0.90 mm
Temperature control
– Section 1
– Section 2
– Section 3
– Section 4
– Head
– Pump
– Die
– Melt
265 °C
275 °C
270 °C
265 °C
270 °C
270 °C
270 °C
270 °C
260 °C
265 °C
260 °C
255 °C
260 °C
260 °C
260 °C
260 °C
Water bath temperature
Die spacing
Cooling path length
70 °C
160 mm
900 mm
45 °C
40 mm
780 mm
Take-off rate
Stretching temperature
(hot air), 1st heater
Stretching unit 1
Stretching temperature
(hot air), 2nd heater
Stretching unit 2
Fixing temperature,
3rd heater, 20 m/min
Fixing unit
20 m /min
155 °C
25 m /min
160 °C
80 m /min
235 °C
112.5 m /min
–
110 m /min
230 °C
–
200 °C
101.2 m /min
101.3 m /min
Stretching ratio 1
Stretching ratio 2
Overall stretching ratio
Mechanical shrinkage
1 : 4.0
1 : 1.38
1 : 5.5
8 %
1 : 4.5
–
1 : 4.5
10 %
Gas transmission
– Water vapor
g /(m2 · d)
transmission
rate
ml /(m2 · d)
– Nitrogen gas
transmission
rate
ml /(m2 · d · bar)
– Oxygen
permeability
– Carbon dioxide ml /(m2 · d · bar)
permeability
10
ASTM F 1249
12
ASTM D 3985-81
60
550
Optical properties
Haze
%
1
ASTM D 1003
Table 8: Properties of film made from Ultradur® B 4500
(film thickness approx. 25 µm, measured in standard atmosphere,
ISO 291, after saturation)
Production of monofilaments and bristles
Monofilaments made from Ultradur® B 2550 for the fabric
sector are produced on commercial extruders. The usual
monofilament diameters lie in the range of 0.5 mm to 1.0 mm.
To achieve good uniformity of diameter water spinning bath
temperatures of 60 °C to 80 °C are required when cooling.
In comparison with polyesters made from polyethylene
terephthalate­ Ultradur® exhibits better resistance to hydrolysis.
ø 45 mm
L / D = 25
three-section screw,
6 D / 7 D / 9 D + 3 D
Table 9: Processing examples for the production of m
­ onofilaments
and bristles from Ultradur®
Bristles for e. g. toothbrushes can be extruded from Ultradur®
B 2550. Finishing treatments in the autoclave or in hot water
baths for ­improving the ability to return to the upright position are not a
­ bsolutely necessary. Toothbrush bristles made
from Ultradur® are distinguished primarily by low water absorption, high resistance to abrasion and excellent powers of
return to the upright position. Examples of the production of
monofilaments and bristles from U
­ ltradur® are presented in
Table 9.
Snowboard
38
THE PROCESSING OF Ultradur®
Fabrication and finishing processes
Fabrication and finishing processes
Machining
Semi-finished parts and moldings made from Ultradur® can
be readily machined with cutting tools. This includes drilling,
turning on a lathe, tapping, sawing, milling, filing and grinding. Special tools are not necessary. Machining is possible
using standard tools suitable for machining steel on all standard machine tools.
As a general rule cutting speeds should be high and feed
rate low with rapid removal of shavings and chips. The cutting tools must always be sharp. Since Ultradur® has a high
softening point cooling is generally not required. However,
the working conditions must be chosen in such a way that
the temperatures do not exceed 200 °C.
Joining methods
Parts made from Ultradur® can be joined at low cost by a
variety of methods. The mechanical properties of Ultradur®,
especially its toughness, allow the use of self-tapping screws.
Ultradur® parts can be connected without difficulty to one
another or to parts made from other materials by means of
rivets and bolts. Ultradur®’s outstanding elasticity and strength,
even at high temperatures, enables economic manufacture
of high-performance snap- and press-fitting connectors.
Ultradur® parts can be bonded to other parts made of this
or another material using two-component adhesives based
on epoxide resins, polyurethanes, silicones or even cyanoacrylates. The highest bonding strengths can be achieved
when the surfaces to be joined together are roughened and
degreased with a solvent such as acetone.
Known methods for welding Ultradur® include heatingelement and ultrasonic welding as well as spin and vibration
welding. As an especially gentle joining technique laser welding can be used, e. g. when sensitive electrical assemblies
must not be submitted to the mechanical and thermal
stresses of the other joining methods. Only high-frequency
welding is not feasible for this plastic on account of the low
dielectric loss factor. Due to its range of variation the ultrasonic joining technique in particular affords the possibility of
integrating the bonding of mass-produced injection-molded
parts efficiently and synchronously into fully automated production flows. Design of the mating surfaces in line with the
welding technique together with optimum processing parameters are the prerequisites for obtaining high-quality welded
joints. It is therefore important to consider at the design
stage how parts are to be welded and then to design the
mating surfaces accordingly.
Further details can be found in the corresponding guidelines
of the DVS ( Deutscher Verband für Schweißtechnik = German
association for welding technology ). Ultrasound also can be
used to embed metal inserts into preformed holes.
Air flow sensor
THE PROCESSING OF Ultradur®
Fabrication and finishing processes
39
Steering angle sensor
Laser marking
Very good results are also obtained with laser-printing on
Ultradur® moldings. There is an abundance of experience in
this area which the Ultraplaste Infopoint can inform customers about. Special tints for high-contrast laser-lettering are
available. Our LS types are especially suited for that method.
Door handle module
40
GENERAL INFORMATION
Safety notes
General Information
Safety notes
Safety precautions during processing
If processing takes place under the recommended conditions
(according to the product-specific processing data sheets),
melts made of Ultradur® are thermally stable and do not pose
any hazards due to molecular degradation or the evolution
of gases and vapors. Like all thermoplastic polymers, however, Ultradur® decomposes on exposure to excessive thermal stresses, e. g. when it is overheated or as a result of
cleaning by burning off. In such cases gaseous decomposition products are formed. Further information can be found
in the product-specific safety data sheets.
When Ultradur® is properly processed and there is adequate
suction at the die, no risks to health are to be expected. The
workplace should be adequately ventilated when Ultradur®
is being processed.
Incorrect processing includes e. g. high thermal stresses and
long residence times in the processing machine. In these
cases there is the risk of elimination of pungent-smelling
vapors and gases which can be a hazard to health. Such a
failure additionally becomes apparent due to brownish burn
marks on the moldings.
When relatively long downtimes occur it is therefore necessary to flush the cylinder empty or to purge it with an
Ultradur® grade which is not flame-retardant and lower the
temperature. In general we recommend careful e
­ xtraction
by suction in the area of the nozzle. In the event of fires
involving flame-retardant grades containing halogen, toxic
compounds can be produced which should not be inhaled.
Further information can be found in the safety data sheets.
Toxicological information, regulations
No detrimental effects to people engaged in the processing
of Ultradur® have come to be known when the material has
been correctly processed and the work areas have been well
ventilated.
Food safety regulations
Some standard-grades of the Ultradur® product line are in
conformity with the current regulations for food contact in
Europe and USA with respect to their composition and
manufacturing conditions. BASF will be glad to provide the
relevant confirmations on request (plastics.safety@basf.com).
Delivery
This is remedied by ejection of the machine contents into
the open air and reducing the cylinder temperature at the
same time. Rapid cooling of the damaged material, e. g. in a
water bath, reduces nuisances caused by odors. In general
measures should be taken to ensure ventilation and venting
of the work area, preferably by means of an extraction hood
over the cylinder unit. Halogen-containing flame-retardant
Ultradur® grades can give rise to corrosive and harmful
degradation products due to overheating or long residence
times of the melt in the cylinder.
Standard packaging includes the 25-kg bag and the 1,000 kg
octabin (octagonal container). Other forms of packaging are
possible subject to agreement. All containers are tightly sealed
and should be opened only immediately prior to processing.
Further precautions for preliminary treatment and drying are
described in the processing section of the brochure. The bulk
density is depending on the product about 0.5 to 0.8 g / cm3.
GENERAL INFORMATION
Ultradur ® and the environment
41
Ultradur® and the environment
Quality and environmental management
Storage and transportation
Under normal conditions Ultradur® can be stored for unlimited p
­ eriods. Even at elevated temperatures, e. g. 40 °C in air,
and under the action of sunlight and weather no decomposition reactions occur (cf. sections “Delivery” and “Behavior
on exposure to weather”).
Quality and environmental management are an integral part
of BASF’s corporate policy. One key objective is to ensure
customer satisfaction. A priority is to continuously improve
our products and services with regard to quality, environmental friendliness, safety, and health. The business unit
Engineering Plastics Europe has a quality and environmental
management system, which was approved by the German
Society for Certification of Management Systems (DQS):
Ultradur® is not a hazardous material as defined by the
CLP Ordinance (EG) No. 1272 / 2008 and hence is not a
hazardous material for transportation. Further information
can be found in the product-specific safety data sheets.
Ultradur® is assigned as not water-hazardous.
Waste disposal
In compliance with official regulations Ultradur® can be
dumped or incinerated together with household garbage.
The calorific value of unreinforced grades amounts to
29,000 to 32,000 kJ / kg (Hu according to DIN 51900). The
burning behavior of Ultradur® is described in the section
“The properties of Ultradur®”.
Quality management system in accordance with ISO 9001
and ISO / TS 16949
Environmental management system in accordance with
ISO 14001.
The certification covers all services by the business unit in
terms of the development, production, marketing, and distribution of engineering plastics. In-house and external audits
as well as training programs for employees are conducted
on a regular basis to ensure the reliable functionality and continuous development of the management systems.
Halogen-containing flame-retardant Ultradur® grades are
classed as hazardous waste and have to be disposed of in
accordance with the requirements of national waste law and
the local regulations.
Recovery
Like other production wastes, sorted Ultradur® waste materials, e. g. ground up injection-molded parts and the like, can
be fed back to a certain extent into processing depending on
the grade and the demands placed on it. In order to produce defect-free injection-molded parts containing regenerated material the ground material must be clean and dry
(drying is usually necessary ). It is also essential that no thermal degradation has occurred in the preceding processing.
The maximum permissible amount of regrind that can be
added should be determined in trials. It depends on the
grade of Ultradur®, the type of injection-molded part and on
the requirements. The properties of the parts, e. g. impact
and mechanical strength, and also processing behavior,
such as flow properties, shrinkage and surface finish, can be
markedly affected in some grades by even small amounts of
reground material.
ABS/ESP steering sensor
42
GENERAL INFORMATION
Nomenclature
Nomenclature
Structure
The name of Ultradur® commercial products generally
follows the scheme below:
Ultradur®
Subname
Technical ID
Suffixes
Color
Subnames
Subnames are optionally used in order to particularly
emphasize a product feature that is characteristic of part of
a range.
Example of subnames:
LUXParticularly high transparency to the radiation from
Nd:YAG lasers and lasers of a similar wavelength,
e. g. diode lasers
Technical ID
The technical ID is made up of a series of letters and numbers which give hints about the polymer type, the melt
viscosity and the finish with reinforcing agents, fillers or
modifiers. The following classification scheme is found with
most products:
B
4
3
0
0
G
6
Viscosity class
Polymer type
Type of reinforcing agent /
filler or modifier
Content of reinforcing agent /
filler or modifier
Letters for identifying polymer types
BPolybutylene terephthalate (PBT ) or
polybutylene terephthalate + polyethylene
terephthalate (PET )
SPolybutylene terephthalate + acrylonitrile
styrene acrylate polymer (ASA)
Numbers for identifying viscosity classes
2Low viscosity
4Medium viscosity
6High viscosity
Letters for identifying reinforcing agents,
fillers, and modifiers
GGlass fibers
KGlass beads
MMinerals
ZImpact modifiers
GMGlass fibers in combination with minerals
Key numbers for describing the content of
reinforcing agents, fillers, or modifiers
2approx. 10 % by mass
3approx. 15 % by mass
4approx. 20 % by mass
6approx. 30 % by mass
10approx. 50 % by mass
12approx. 60 % by mass
In the case of combinations of glass fibers with
minerals, the respective contents are indicated by two
numbers, e. g.
GM13approx. 5 % by mass of glass fibers and
approx. 15 % by mass of minerals
GENERAL INFORMATION
Suffixes
Suffixes
Suffixes are optionally used in order to indicate specific
processing or application-related properties. They are
frequently acronyms whose letters are derived from the
English term.
Examples of suffixes:
Aqua®Suitable for cold water applications
FCFood Contact; meets specific
regulatory requirements for applications in
contact with food
High SpeedHigh flowability of the melt
HRHydrolysis Resistant, increased
hydrolysis resistance
LSLaser Sensitive, can be marked with
Nd:YAG laser
LTLaser Transparent, can be penetrated well
with Nd:YAG lasers and lasers of
a similar wavelength
PROSuitable for medical applications
Color
The color is generally made up of a color name
and a color number.
Examples of colors:
Uncolored
Black 00110
Black 05110
Moving platen
43
44
GENERAL INFORMATION
Subject index
Subject index
ABS/ESP steering sensor 41
Absorption of moisture 24
Aftershrinkage 32
Air flow control 11
Air flow sensor 38
Air pressure sensor 15
Applications in contact with food and drinking water 11
Atmospheric moisture 21
Automotive engineering 4 f.
Back pressure 29
Batches 12, 26, 27
Behavior
– on exposure to weather 24, 25
– under cyclic loads, flexural fatigue strength 18
– on brief exposure to heat 20
– under long-term static loading 17
Bristle 9, 12, 34, 36, 37
Bristle filaments 9
Catalysts 10
Change of material 27
Chemicals 11, 24
Chill rolls 36
Cold water applications 11, 42
Compressor 9
Connector 4, 6, 7, 10, 12, 38
Construction industry 23
Cooling path length 37
Creep modulus 17
Delivery 40
Die 35 ff.
Die head diameter 37
Die head length 37
Die spacing 37
Dielectric constant and dissipation factor 22
Door handle module 39
Drill hammer 7
Drilling 38
Drinking water 8, 11, 13
Drying 26, 27, 40
Electrical engineering and electronics 6 f., 22
Electrical insulating materials 23
Electrical properties 4, 6, 22
Elongation 14, 16, 25
Elongation at break 14, 25
Environmental management 41
Exterior mirror housing 25
Extrusion 34 ff.
Extrusion method 35
Fabrication and finishing processes 38 f.
Falling weight test 16
Fibers 12, 20, 34
Fillers 10, 42
Film 8, 9, 10, 12, 26, 31, 34, 36, 37
Film extrusion example 36
Fire behavior 23
Fixing temperature 37
Flame-retardant grades 11, 13, 40
Flexural fatigue strength 18
Flight depth 28, 34, 35, 36
Flow behavior and injection speed 30
Flow properties 10
Food contact 11, 13, 40
Food safety regulations 8, 11, 40
Glass fiber content 10, 14, 17
Glass-fiber reinforced grades 10, 16, 20, 30
Glow wire test 23
Headlamp housing 5
Headlight cover 22
Heater band temperatures 36
Heat aging resistance 20 f.
Household applications 8 f.
Hydrolysis resistance 6, 11, 13, 21
Impact resistance 16, 26
Impact strength 16, 17, 21
Impact tests 16
Impact-failure energy 16, 17
Industrial applications 8 f.
Injection molding 11, 26, 28 ff.
Injection speed 30
Injection Unit 28
Insulating materials 23
Insulin pen 8, 13
Isochronous stress-strain curves 17
GENERAL INFORMATION
Subject index
Joining methods 11, 38
Laser marking 39
Laser transparency 11, 13
Long-term flexural fatigue tests 18
Low-temperature impact resistance 16
Machining 12, 38
Masterbatches 8, 27
Mechanical properties 14 ff.,25, 37, 38
Mechatronic control unit 31
Medical applications 11
Melt pressure 35, 36
Melt temperature 30, 31, 32, 33, 35, 36
Metering 29
Metering and back pressure 29
Mirror actuator housing 4
Mirror arm 5
Modulus of elasticity 14
Moisture 4, 11, 21, 22, 24, 26
Moisture content 4, 22, 24, 26
Mold design 28 f.
Mold surface temperature 30, 32, 33
Mono­filaments 12, 26, 36, 37
Motor circuit breaker 7
Moving platen 43
Nomeclature 42 f.
Normal conditions 17, 18, 41
Operating temperature 18
Optical properties 11, 37
Pipe extrusion head 36
Plasticating unit 30
Plug-in connector 4, 6, 12, 13
Processing 10, 12, 16, 21, 26 ff., 40
Processing temperature and residence time 30
Product range 10 ff.
Production of
– film 36 f.
– monofilaments and bristles 34, 37
– semi-finished products and profile sections 35
– sheet 35
– tubes 36
Production stoppages 27
Production wastes 41
Profile 10, 12, 26, 34, 35
Properties 4, 6, 10 ff., 27, 41
Pump 37
Pump pressure housing 27
Quality and environmental management 41
Rain sensor 4
Recovery 41
Reduction of viscosity number 30
Reflector housing 5
Regulations 23, 40, 41
Reinforced grades 10, 12, 13, 20, 30
Reinforcing agents 42
Reprocessing 27
Residence time 30, 35, 40
Resistance to chemicals and behavior
on exposure to weather 24
Rod extrusion example 35
Roof top frame 26
Safety notes 40
Safety precautions during processing 40
Screw 27, 28, 34, 35, 36, 37, 38
Screw flight depths 28
Screw geometry 28, 34
Screw speed 29, 35, 36
Self-coloring 26, 27
Semi-finished parts 34, 38
Shear modulus 14, 20
Sheet extrusion example 35
Shrinkage behavior 11, 30 ff.
Snowboard 37
Steering angle sensor 39
Storage 20, 21, 24, 31, 32, 41
Storage and transportation 41
Stress relaxation behavior 17
Stress-strain diagrams 16
45
46
GENERAL INFORMATION
Subject index
Take-off speed 15, 16, 35, 36
Tear strength 25, 37
Temperature settings 35, 36
Tensile creep test 17
Tensile load 16
Tensile strength 15, 20, 21, 25
Test box 16, 31, 33
Test rods 16
Tests 18, 19, 20, 23
Thermal endurance graph 20
Thermal properties 20 f.
Three-section screws 28, 34
Torsion pendulum tests 14, 20
Toughness 13, 16, 38
Toxicological information, regulations 40
Toy 9
Transportation 23, 41
Travel adapter 7
Tribological properties 19
Tubes 12, 34, 36
Unreinforced grades 10, 12, 20, 41
Vented screws 27
Warpage 6, 10, 11, 12, 31, 32 f.
Warpage behavior 32, 33
Waste disposal 41
Water bath temperature 37
Water bath vacuum 36
Windscreen wiper arm 4
Window profile reinforcement 8
Yield stress 37
Selected Product Literature for Ultradur®:
Please visit our websites:
www.plasticsportal.com ( World )
www.plasticsportal.eu ( Europe )
Additional information on specific products:
www.plasticsportal.eu /name of product
e. g. www.plasticsportal.eu /ultradur
Request of brochures:
PM / K, F 204
Fax: + 49 621 60 - 49497
If you have technical questions on the products,
please contact the Ultra-Infopoint:
KTED 1304 BE
Note
The data contained in this publication are based on our current knowledge and
experience. In view of the many factors that may affect processing and application
of our product, these data do not relieve processors from carrying out own investigations and tests; neither do these data imply any guarantee of certain properties,
nor the suitability of the product for a specific purpose. Any descriptions, drawings,
photographs, data, proportions, weights etc. given herein may change without prior
information and do not constitute the agreed contractual quality of the product. It
is the responsibility of the recipient of our products to ensure that any proprietary
rights and existing laws and legislation are observed. ( August 2013 )
® = registered trademark of BASF SE
Ultradur® – Product Range
Ultradur® LUX – PBT for Laser Welding
Ultradur® HR – PBT for Hot-damp Environments
Ultramid®, Ultradur® and Ultraform® – Resistance to Chemicals
Engineering Plastics for Medical Solutions – Ultraform® PRO (POM) and Ultradur ® PRO (PBT )
From the Idea to Production – The Aqua® Plastics Portfolio for the Sanitary and Water Industries
Ultramid® and Ultradur® – Engineering Plastics for Photovoltaic Mounting Systems
Engineering Plastics for the E/E Industry – Standards and Ratings
Engineering Plastics for the E/E Industry – Products, Applications, Typical Values
Engineering Plastics for Automotive Electrics – Products, Applications, Typical Values